Twin coil arc sweep system for vacuum arc remelting furnaces

A vacuum arc remelting (VAR) system for forming an ingot from an electrode, the system comprising:

• a crucible assembly configured to accommodate the electrode and the ingot, wherein the crucible assembly includes an upper end portion and a lower end portion;
• a primary electromagnetic energy source arranged about the crucible assembly, wherein the primary electromagnetic energy source and the crucible assembly are configured to move relative to one another along a longitudinal axis of the crucible assembly;
• a secondary electromagnetic energy source arranged about the upper end portion of the crucible assembly, wherein the secondary electromagnetic energy source is stationary and fixed to the upper end portion of the crucible assembly;
• and
• a current controller configured to provide electric current to the primary electromagnetic energy source.

A vacuum arc remelting (VAR) system for forming an ingot from an electrode, the system comprising:

• a crucible assembly configured to accommodate the electrode and the ingot, wherein the crucible assembly includes an upper end portion and a lower end portion;
• a primary electromagnetic energy source arranged about the crucible assembly, wherein the primary electromagnetic energy source and the crucible assembly are configured to move relative to one another along a longitudinal axis of the crucible assembly;
• a secondary electromagnetic energy source arranged about the upper end portion of the crucible assembly, wherein the secondary electromagnetic energy source is stationary and fixed to the upper end portion of the crucible assembly;
• a primary current controller configured to provide electric current to the primary electromagnetic energy source;
• a secondary current controller configured to provide electric current to the secondary electromagnetic energy source;
• and
• a master controller configured to receive process inputs from the primary current controller and the secondary current controller and to provide current settings to each of the primary current controller and the secondary current controller based on the process inputs, the master controller further configured to communicate with a main VAR furnace controller,
• wherein the process inputs comprise position of the primary electromagnetic energy source and electric current being provided to each of the primary electromagnetic energy source and the secondary electromagnetic energy source, and
• wherein magnetic fields generated by the primary electromagnetic energy source and the secondary electromagnetic energy source are localized to an arc region during remelting.

A vacuum arc remelting (VAR) system for forming an ingot from an electrode, the system comprising:

• a crucible assembly configured to accommodate the electrode and the ingot, wherein the crucible assembly includes an upper end portion and a lower end portion;
• an axial electromagnetic energy source wound about the longitudinal axis of the crucible assembly;
• a primary electromagnetic energy source arranged about the crucible assembly, wherein the primary electromagnetic energy source and the crucible assembly are configured to move relative to one another along a longitudinal axis of the crucible assembly;
• and
• a secondary electromagnetic energy source arranged about the upper end portion of the crucible assembly, wherein the secondary electromagnetic energy source is stationary and fixed to the upper end portion of the crucible assembly.